Integrated Inverter Power Module Assembly for Flexible Motor Windings
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Solution Overview
Problem
Inverter circuits for high voltage applications, such as electric vehicles, face challenges with increased heat generation, complex control, and excessive high voltage cabling due to various winding configurations of motors, which complicate cooling and fault safety.
Innovation Solution
A highly integrated power switch module topology with dual inverters housed together, utilizing SiC MOSFETs and a changeover switch to simplify internal assembly, enable efficient fault safety, and reduce cooling complexity, while allowing reconfiguration between Delta and Wye winding configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional high voltage cabling and complicated control are used to support various winding configurations, then the inverter can manipulate torque and power output curves, but the device complexity and heat generation increase excessively
Solution Approach 1:
The patent combines multiple power modules (first and second power modules with respective inverters) into a single integrated system with shared DC rails and coordinated control. This merging approach maintains the ability to support various winding configurations (Delta, Wye, Open-Ended Wye) while reducing overall system complexity by consolidating cabling and control architecture compared to separate independent inverter systems.
2Adaptability or versatility
If additional high voltage cabling is used to support various winding configurations, then the inverter can manipulate torque and power output curves, but heat generation increases excessively
Solution Approach 1:
The integrated power module design consolidates multiple inverters and power switches into a unified structure with shared DC power distribution rails. This merging reduces the total length and number of high voltage cabling connections required to support various winding configurations, thereby reducing I2R losses and heat generation while maintaining configuration flexibility.
3Loss of energy
If dual inverters are housed together in a highly integrated power module, then switching losses are reduced and cooling complexity is simplified, but the manufacturing precision requirements increase
Solution Approach 1:
The patent integrates first and second power modules with their respective inverters into a single compact housing with shared DC rails and coordinated power switches. This merging reduces the number of external connections and cabling required, minimizing switching losses. The integrated design also simplifies thermal management by consolidating heat-generating components into a unified structure with centralized cooling, though it does require precise manufacturing and assembly tolerances.
Data Source
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AI summary
Disclosed solutions relate to electrical inverters. In an example, an inverter to convert DC power from a voltage source to AC power to drive a motor is disclosed. The inverter includes a first power module. The first power module includes first phase switches, second phase switches and positive DC power tabs connected to a positive DC rail to provide positive DC power to the first phase switches and the second phase switches. The inverter further includes negative DC power tabs connected to a negative DC rail to provide negative DC power to the first phase switches and the second phase switches. The inverter further includes first phase AC power tabs to receive AC power from the first phase switches. The inverter further includes second phase AC power tabs to receive AC power from the second phase switches.